CQI-12 Coating System 3-8-12 Final

CQI-12v2
Special Process: Coating System Assessment
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2012 Automotive Industry Action Group, except that copyright is not claimed as to any part
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2012 Automotive Industry Action Group
2012 Automotive Industry Action Group
ISBN#: 978-1-60534-245-0-90000
CQI-12v2
Dated: 2/2012
CQI-12
Version 2 Issued 2/2012
Special Process: Coating System Assessment 2nd Edition

Facility Name:
Address:
Phone Number:
Fax Number:
Number of Coating Employees at this Facility:
Captive Coater (Y/N):
Commercial Coater (Y/N):
Date of Assessment:
Date of Previous Assessment:
Type(s) of Coating Processes at this Facility:

Process Table A
Pretreatment, Aqueous
Process Table B
Pretreatment, Mechanical
Process Table C
Conversion Coating
Process Table D
Powder Coating
Process Table E
Spray
Process Table F
Electrocoat
Process Table G
Dip/Spin
Process Table H
Autodeposition
Process Table I
Cure
Process Table J
Anodizing
Process Table K
Equipment
Process Table L
Part Inspection & Testing
Current Quality Certification(s):

Date of Re-assessment (if necessary):
Personnel Contacted:
Name:
Title:
Phone:
Email:
Auditors/Assessors:
Name:
Company:
Phone:
Email:
Number of "Not Satisfactory" Findings:
Number of "Needs Immediate Action" Findings:
Number of "Fail" Findings in the Job Audit(s):
Number of Process Table Items not meeting Minimum Requirements:
2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question
Number
Question
Requirements and Guidance
Objective Evidence
N/A
Section 1 - Management Responsibility and Quality Planning
1.1
1.2
Is there a dedicated and

qualified coating person onsite?
To ensure readily available expertise, there shall be a

dedicated and qualified coating person on the site.
This individual shall be a full-time employee and the
position shall be reflected in the organization chart. A
job description shall exist identifying the qualifications
for the position including chemical and coating
knowledge. The qualifications shall include a
minimum of 5 years experience in coating operation or
a combination of a minimum of 5 years of formal
chemical education and coating experience.
Does the coater perform

advanced quality planning?
The coater shall incorporate a documented advanced

quality planning procedure. A feasibility study shall be
performed and internally approved for each new part
or process. Similar parts can be grouped into part
families for this effort as defined by the coater. After
the part approval process is approved by the
customer, no process changes are allowed unless
approved by the customer. The coater shall contact
the customer when clarification of process changes is
required. This clarification of process changes shall
be documented.
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
1.3
The coater shall incorporate the use of a documented

Failure Mode and Effects Analysis (FMEA) procedure
and ensure the FMEAs are updated to reflect current
part quality status. The FMEA shall be written for each
part or part family or they may be process-specific and
Are the coater's FMEA's up to written for each process. In any case, they shall
date and reflecting current
address all process steps from part receipt to part
processing?
shipment and all key coating process parameters as
defined by the coater. A cross-functional team shall be
used in the development of the FMEA. All special
characteristics, as defined by the coater and its
customers, shall be identified, defined, and addressed
in the FMEA.
1.4
The coater shall incorporate the use of a documented

Control Plan procedure and ensure the Control Plans
are updated to reflect current controls. The Control
Plans shall be written for each part or part family or
they may be process-specific and written for each
process. In any case, they shall address all process
steps from part receipt to part shipment and identify all
equipment used and all key coating process
parameters as defined by the coater. A crossAre finish process Control
functional team, including a production operator, shall
Plans up to date and reflecting
be used in the development of Control Plans, which
current processing?
shall be consistent with all associated documentation
such as work instructions, shop travelers, and FMEAs.
All special characteristics, as defined by the coater
and its customers, shall be identified, defined, and
addressed in the Control Plans. Sample sizes and
frequencies for evaluation of process and product
characteristics shall also be addressed consistent with
the minimum requirements listed in the Process
Tables.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
1.5
1.6
Question
Are all coating related and

referenced specifications
current and available? For
example: SAE, AIAG, ASTM,
General Motors, Ford, and
Chrysler.
To ensure all customer requirements are both

understood and satisfied, the coater shall have all
related coating and customer referenced standards
and specifications available for use and a method to
ensure that they are current. Such standards and
specifications include, but are not limited to, those
relevant documents published by SAE, AIAG, ASTM,
General Motors, Ford, and Chrysler. The coater shall
have a process to ensure the timely review,
distribution, and implementation of all customer and
industry engineering standards and specifications and
changes based on customer-required schedule. This
process shall be executed as soon as possible and
shall not exceed two weeks. The coater shall
document this process of review and implementation,
and it shall address how customer and industry
documents are obtained, how they are maintained
within the coater, how the current status is established,
and how the relevant information is cascaded to the
shop floor within the two-week period. The coater shall
identify who is responsible for performing these tasks.
Is there a written process

specification for all active
processes?
The coater shall have written process specifications for

all active processes and identify all steps of the
process including relevant operating parameters.
Examples of operating parameters include process
temperatures, cycle times, load rates, rectifier settings,
etc. Such parameters shall not only be defined, they
shall have operating tolerances as defined by the
coater in order to maintain process control. All active
processes should have a written process specification.
These process specifications may take the form of
work instructions, job card, computer-based recipes, or
other similar documents.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
1.7
To demonstrate each process is capable of yielding

acceptable product, the coater shall perform product
capability studies for the initial validation of each
process, after relocation of any process equipment,
and after a major rebuild of any equipment. The coater
shall define what constitutes a major rebuild. Initial
product capability studies shall be conducted for all
coating processes per line as defined in scope of work
Has a valid product capability
and in accordance with customer requirements.
study been performed initially
Capability study techniques shall be appropriate for
and after process change?
the coating product characteristics, e.g., coating
thickness, corrosion resistance, etc.. Any specific
customer requirements shall be met. In the absence of
customer requirements, the coater shall establish
acceptable ranges for measures of capability. An
action plan shall exist to address the steps to be
followed in case capability indices fall outside
customer requirements or established ranges.
1.8
The analysis of products and processes over time can

yield vital information for defect prevention efforts.
The coater shall have a system to collect, analyze, and
Does the coater collect and
react to product or process data over time. Methods of
analyze data over time, and
analysis shall include ongoing trend or historical data
react to this data? Are records analysis of special product or process parameters.
available?
The coater shall determine which parameters to
include in such analysis. All process control and
testing records must be retained for a minimum of one
calendar year after the year in which they were
created.
1.9
Are internal assessments

The coater shall conduct internal assessments on an
being completed on an annual
annual basis, at a minimum, using the AIAG CSA.
basis, at a minimum,
Concerns shall be addressed in a timely manner.
incorporating AIAG CSA?
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
1.10
The quality management system shall include a

documented process for reprocessing that shall
include authorization from a designated individual.
The reprocessing procedure shall describe product
characteristics for which reprocessing is allowed as
Is there a system in place to well as those characteristics for which reprocessing is
authorize reprocessing and is not permissible. All reprocessing activity shall require
it documented?
a new processing control sheet issued by qualified
technical personnel denoting the necessary coating
modifications. Records shall clearly indicate when and
how any material has been reprocessed. The Quality
Manager or a designee shall authorize the release of
reprocessed product.
1.11
Does the Quality Department

review, address, and
document customer and
internal concerns?
1.12
The coater shall define a process for continual

improvement for each coating process identified in the
Is there a continual
scope of the CSA. The process shall be designed to
improvement plan applicable
bring about continual improvement in quality and
to each process defined in the
productivity. Identified actions shall be prioritized and
scope of the assessment?
shall include timing (estimated completion dates). The
coater shall show evidence of program effectiveness.
1.13
Does the Quality Manager or

designee authorize the
disposition of material from
quarantine status?
The quality management system shall include a

process for documenting, reviewing, and addressing
customer concerns and any other concerns internal to
the coater. A disciplined problem solving approach
shall be used.
The Quality Manager or designee is responsible for

authorizing and documenting appropriate personnel to
disposition quarantine material.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
There shall be procedures or work instructions

available to coating personnel covering the coating
process. These procedures or work instructions shall
include methods of addressing potential emergencies
(such as power failure), equipment start-up, equipment
shut-down, product segregation (See 2.8), product
inspection, and general operating procedures. These
procedures or work instructions shall be accessible to
shop floor personnel.
1.14
Are there procedures or work

instructions available to
coating personnel that define
the coating process?
1.15
The coater shall provide employee training for all

coating operations. All employees, including backup
and temporary employees, shall be trained.
Documented evidence shall be maintained showing
Is management providing
the employees trained and the evidence shall include
employee training for coating?
an assessment of the effectiveness of the training.
Management shall define the qualification
requirements for each function, and ongoing or followup training shall also be addressed.
1.16
Is there a responsibility matrix

to ensure that all key
management and supervisory
functions are performed by
qualified personnel?
The coater shall maintain a responsibility matrix

identifying all key management and supervisory
functions and the qualified personnel who may
perform such functions. It shall identify both primary
and secondary (backup) personnel for the key
functions (as defined by the coater). This matrix shall
be readily available to management at all times.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
1.17
1.18
Question
Is there a preventive
maintenance program? Is
maintenance data being
utilized to form a predictive
maintenance program?
The coater shall have a documented preventive

maintenance program for key process equipment (as
identified by the coater). The program shall be a
closed-loop process that tracks maintenance efforts
from request to completion to assessment of
effectiveness. Equipment operators shall have the
opportunity to report problems, and problems shall
also be handled in a closed-loop manner. Company
data, e.g., downtime, quality rejects, first time-through
capability, recurring maintenance work orders, and
operator-reported problems, shall be used to improve
the preventive maintenance program. Maintenance
data shall be collected and analyzed as part of a
predictive maintenance program.
Has the coater developed a

The coater shall develop and maintain a critical spare
critical spare parts list, and are
parts list and shall ensure the availability of such parts
the parts available to minimize
to minimize production disruptions.
production disruptions?
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
Objective Evidence
N/A
Section 2 - Floor and Material Handling Responsibility

Does the facility ensure that
the data entered in the
receiving system matches the
information on the customer's
shipping documents?
Documented processes and evidence of compliance

shall exist, e.g., shop travelers, work orders, etc. The
facility shall have a detailed process in place to resolve
receiving discrepancies.
2.2
Is product clearly identified

and staged throughout the
coating process?
Procedures for part and container identification help to

avoid incorrect processing or mixing of lots.
Appropriate location and staging within the facility also
help to ensure that orders are not shipped until all
required operations are performed. Customer product
shall be clearly identified and staged throughout the
coating process. Non-coated, in-process, and finished
product shall be properly segregated and identified. All
material shall be staged in a dedicated and clearly
defined area.
2.3
Is lot traceability and integrity

maintained throughout all
processes?
Out-going lot(s) shall be traceable to the incoming

lot(s). The discipline of precisely identifying lots and
linking all pertinent information to them enhances the
ability to do root cause analysis and continual
improvement.
Are procedures adequate to

prevent movement of nonconforming product into the
production system?
The control of suspect or non-conforming product is

necessary to prevent inadvertent shipment or
contamination of other lots. Procedures shall be
adequate to prevent movement of non-conforming
product into the production system. Procedures shall
exist addressing proper disposition, product
identification and tracking of material flow in and out of
hold area. Non-conforming hold area shall be clearly
designated to maintain segregation of such material.
2.1
2.4
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
2.5
2.6
2.7
Question
Is there a system to identify

trap points in the entire
process to reduce risk of
mixed parts (inappropriate,
unfinished or improperly
coated parts)?
The coater shall have documented procedures to

identify and monitor trap points for each
process/equipment. Monitoring of potential trap points
shall occur for every part changeover.
Are containers free of

inappropriate material?
Containers handling customer product shall be free of

inappropriate material. After emptying and before reusing containers, containers shall be inspected to
ensure that all parts and inappropriate material have
been removed. The source of inappropriate material
shall be identified and addressed. This is to ensure
that no nonconforming coated parts or inappropriate
material contaminate the finished lot.
Is part loading specified,

documented and controlled?
Loading parameters shall be specified, documented

and controlled. Examples include parts per rack and
load size.
Refer to Process Tables for frequency of checks.
2.8
Unplanned or emergency downtime greatly raises the

risk of improper processing. Operators shall be trained
in material handling, containment action, and product
Are operators trained in
segregation in the event of an equipment emergency
material handling, containment including power failure. Training shall be documented.
action and product
Work instructions specifically addressing potential
segregation in the event of an types of equipment emergencies and failures shall be
equipment emergency
accessible to and understood by equipment operators.
including power failure?
These instructions shall address containment/reaction
plans related to all elements of the process. Evidence
shall exist showing disposition and traceability of
affected product.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
2.9
Question
Is the handling, storage and

packaging adequate to
preserve product quality?
The coater's loading/unloading systems, in-process

handling and shipping process shall be assessed for
risk of part damage or other quality concerns.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
2.10
Plant cleanliness, housekeeping, environmental, and

working conditions shall be conducive to controlling
Are plant cleanliness,
and improving quality. The coater should evaluate
housekeeping, environmental
such conditions and their effect on quality. A
and working conditions
housekeeping policy shall be clearly defined and
conducive to control and
executed. The facility shall be reviewed for the
improved quality?
following items: loose parts on floor; spillage around
tanks; overall plant lighting; fumes etc.
2.11
Are process control

parameters monitored per
frequencies specified in
Process Tables?
2.12
There are documented reaction plans to both out of

Are out of control/specification
control and out of tolerance process parameters.
parameters reviewed and
There is documented evidence that reaction plans are
reacted to?
followed.
2.13
Are In-Process / Final Test

Frequencies performed as
specified in Process Tables?
2.14
Is product test equipment

verified?
Process control parameters shall be monitored per

frequencies specified in Process Tables. Computer
monitoring equipment with alarms and alarm logs
satisfy the verification requirement. A designated floor
person shall verify the process parameters, e.g., by
initialing a strip chart or data log.
In-Process / Final Test Frequencies shall be performed

as specified in Process Tables. Refer to Process
Tables.
Test equipment shall be verified/calibrated per

applicable customer specific standard or per an
applicable consensus standard, e.g., ASTM, SAE,
ISO, NIST, etc. Verification/calibration results shall be
internally reviewed, approved and documented.
Refer to Process Tables for frequency of checks.
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Assessment
Question
Number
Question
Is lighting of inspection area

adequate?
Lighting in the inspection area must be sufficient to

allow the evaluation of all part surfaces. The lighting
shall be arranged to preclude spot lighting, glare or
shadows. There can be no moving or distracting
reflections on the surfaces to be evaluated.
2.16
Are the water rinse Control

Plans up to date and reflect
best case practices?
Identify operating parameters including:

- number of rinse tanks between process stages,
- tank type (single rinse, counter flowing, stationary
rinse, spray rinse)
- flow rate,
- water requirements (city or deionized water, reverse
osmosis),
- filtration (if applicable)
- control methods
- temperature (if applicable)
2.17
Aware of water quality and it's impact on each specific

Is the water quality adequate? process. Purified water is used where necessary, or
where specified.
2.15
Objective Evidence
N/A
Satisfactory
Not Satisfactory
Needs Immediate
Action
CQI-12
Section 3 - Job Audit - Finished Product Review

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Coating Requirements:
Question #
Job Audit Question
Related
CSA Question #
Customer or Internal
Requirement
Job (Shop) Order or Reference

Documentation Requirement
3.1
Is contract review and advanced quality

planning, FMEA, Control Plans, etc.,
performed by qualified individuals?
1.1
1.2
1.3
1.4
1.6
N/A
3.2
Does the coater have the proper customer

specifications for the part?
1.5
N/A
3.3
Is a shop traveler created to meet

customer requirements?
1.6
2.1
3.4
Is material identification (part numbers, lot

numbers, contract numbers, etc.)
maintained throughout the coating
process?
2.2
2.3
2.4
3.5
Is there documented evidence of

Receiving Inspection?
2.1
3.6
Are the Loading / Racking requirements

identified?
1.6
2.7
2.9
Actual Condition
(Objective Evidence)
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question
Related
CSA Question #
3.7
Is the proper procedure or process

specification used? Refer to Process
Tables for specific parameters. List
parameters that were verified in this audit
in the spaces provided below.
1.5
1.6
2.1
2.11
2.13
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question
3.8
What are the product inspection

requirements?
3.8.1
Requirement: Coating Thickness

Test Method:
Test frequency or quantity:
Selection of samples:
Specification:
3.8.2
Requirement: Corrosion Resistance (if

applicable)
Test Method(s):
Specification:
3.8.3
Requirement: Hydrogen Embrittlement

Relief (if applicable)
Test Method:
Related
CSA Question #
1.5
2.13
Requirement

Actual Condition
Each part may have one or more requirements determined by the coating specification.
Parts must meet each requirement. List each requirement below and validate.
2.14
(Listed below are some examples)
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question

Specification:
3.8.4
Requirement: Adhesion
Test Method(s):
Specification:
3.8.5
Requirement: Cure
Test Method:
Specification:
3.8.6
Requirement: Torque Tension

(if applicable)
Test Method:
Related
CSA Question #
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question

Related
CSA Question #
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question

Specification:
3.8.7
Requirement: Appearance (Decorative)

Test Method:
Specification:
3.8.8
Requirement: Dimensional
(if applicable)
Test Method:
Specification:
3.8.9
Requirement: Color and Gloss

(Decorative)
Test Method:
Specification:
Related
CSA Question #
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
3.8.10
Job Audit Question
Related
CSA Question #
Requirement: Customer Specific

Test Method(s):
Specification:
Operator or Inspector Responsibilities
3.9
Were appropriate process steps signed

off?
3.10
Were all inspection steps, as documented

in the Control Plan performed?
1.4
1.6
2.2
2.3
2.11
1.2
1.4
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question
Related
CSA Question #
3.11
Were steps/operations performed that

were not documented in the Control Plan?
1.2
1.4
1.6
3.12
If additional steps were performed, were

they authorized?
1.2
1.4
1.6
1.10
1.16
3.13
Does the governing specification allow

reprocessing or rework?
1.5
1.10
3.14
If the order was certified, did the

certification accurately reflect the process
performed?
2.11
2.13
3.15
Was the certification signed by an

authorized individual?
1.16
3.16
Are the parts and containers free of

inappropriate objects or contamination?
2.6
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Question #
Job Audit Question
Related
CSA Question #
Packaging Requirements
3.17
Are packaging requirements identified?
2.6
2.7
2.9
3.18
Are parts packaged to minimize mixed

parts (for example, parts packed over
height of container)?
2.6
2.7
2.9
Shipping Requirements
3.19
Were the parts properly identified?
2.3
2.9
3.20
Were the containers properly labeled?
2.3
2.9
Requirement

Actual Condition
Pass / Fail
/ N/A
CQI-12
PROCESS TABLE A - Pretreatment (Aqueous)

All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related
CSA
Question #
Category/Process Steps
Type of Control
Minimum
Requirement
1.0
A1.1
A1.2
Actual Condition
Monitoring Frequency
Minimum Requirement
AQUEOUS CLEANING PROCESS (Alkaline or Acid)

1.4
1.4
1.6
2.11
2.12
There shall be an incoming part assessment procedure

Per Control Plan
with criteria.
Time
Automatic/Manual
Once per lot and per part change

Automatic Line: Confirm set-up at the start
of production and every process change.
Manually verify every 3 months or after
programming change or equipment
maintenance.
Manual Line: Continuously monitor time in
each stage of process.
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum
Requirement
2.0
Actual Condition
Minimum Requirement
Cleaning / Descaling Solution
A2.1
1.4
2.11
2.12
Pressure for spray rinse.

Agitation for immersion tanks.
Automatic/Manual
Once every 8 hours
A2.2
1.4
2.11
2.12
Temperature
Automatic
Continuous monitoring by controller.

Manually verify daily.
A2.3
1.4
1.6
2.11
2.12
Chemical Concentration (Alkaline Cleaner) (If used)

Per chemical supplier recommendation such as:
- free alkalinity
- total alkalinity
- pH
- conductivity
- percentage of cleaner (weight/volume or
volume/volume)
Automatic/Manual
For continuous operations, once per day.

Otherwise, prior to start of each production
cycle.
A2.4
1.4
1.6
2.11
2.12
Chemical Concentration (Acid Cleaner) (If used)

- free acidity or concentration
- metal contamination
Automatic/Manual
For continuous operations, once per day.

Otherwise, prior to start of each production
day. (once per day for concentration, once
per month for contamination).
A2.5
1.4
2.11
2.12
Impurity Content
- acid split (oil contamination)
- alkalinity ratio
Manual
Once per week*
A2.6
2.11
There is a tank maintenance schedule for cleaning

baths.
Manual
Per preventative maintenance program
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum
Requirement
3.0
Actual Condition
Minimum Requirement
Rinse(s)
A3.1
1.4
2.11
2.12

Agitation or flow for immersion tanks.
Automatic/Manual
Once every 8 hours
A3.2
1.4
2.11
2.12
Temperature (if controlled)
Automatic

Manually verify once per day.
A3.3
1.4
2.11
2.12
Cleanliness of last cleaner rinse

- alkalinity/pH/conductivity
- visual inspection for oil or suspended contaminants
- overflow
Manual
Once per day
A3.4
2.11
There is a dump schedule for rinses.
Manual
Per preventative maintenance schedule.
A3.5
A3.6
1.4
2.11
1.4
2.11
There is a visual inspection (e.g. water break) after

each post cleaning rinse bath (not applicable for closed Manual
barrel systems).
Once every 8 hours
Corrosion inhibitor concentration is checked. (If used)
Once every 8 hours
Automatic/Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum
Requirement
4.0
Actual Condition
Minimum Requirement
Acid Pickling
A4.1
1.4
2.11
2.13
A4.2
1.4
2.11
2.12
A4.3
A4.4
Concentration
Manual
Once every 8 hours
Concentration of Fe, per coating supplier.
Manual
Once per day
1.4
2.11
2.12
Inhibitor (if used)
Manual
N/A
1.4
2.11
2.12
Solution Level
Manual
Once every 8 hours
A4.5
Rinse - See Section 3.0.
5.0
Aluminum Etching
A5.1
1.4
2.11
2.12
Concentration
Manual
Once every 8 hours
A5.2
1.4
2.11
2.12
Concentrations of Al, per coating supplier.
Manual
Once per day
A5.3
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum
Requirement
6.0
Actual Condition
Minimum Requirement
Aluminum Deoxidizing
A6.1
1.4
2.11
2.12
Concentration
Manual
Once every 8 hours
A6.2
1.4
2.11
2.12
Concentrations of Al, per coating supplier.
Manual
Once per day
Temperature (if applicable)
Automatic
Manually measure once every 8 hours
A6.3
7.0
Sealing Rinse (if applicable)
A7.1
1.4
2.11
2.13
A7.2
1.4
2.11
2.12
Concentration
Manual
Once every 8 hours
A7.3
1.4
2.11
2.12
Solution Level
Manual
Once every 8 hours
A7.4
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE B - Pretreatment (Mechanical)

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
Actual Condition
Minimum Requirement
ABRASIVE BLAST PROCESS
B1.1
1.4
There shall be an incoming part assessment procedure

with criteria. (Parts have been pre-cleaned and are free Manual
of oil and grease contaminations).
B1.2
2.11
The following checks shall be performed during

production:
Per load
B1.3
Load Weight
Manual / Automatic
Per load
B1.4
Blasting Media Size / type
Manual
Per load
B1.5
B1.6
1.4
1.6
2.11
2.12
Dwell time is clearly defined.

If additional blasting is required, management approval Manual / Automatic
is needed.
Per load
Blasting force is set and maintained within control limits

Manual / Automatic
(Amperage Draw).
Per load
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE B - Pretreatment (Mechanical)

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
B1.7
1.4
1.6
2.11
2.12
Abrasive media level
Manual
Once every 8 hours
B1.8
1.4
2.11
2.12
Dust collector efficiency/air flow
Manual
Once every 4 hours
B1.9
1.4
2.11
2.12
Blasting media size / life:

Media size is being checked on a regular schedule to
determine effective cleaning and life for product mix.
Manual / Automatic
Once per week
B1.10
B1.11
1.4
2.11
1.4
2.11
2.13
Surface cleanliness is checked after process. Surface

cleanliness check must be conducted using a chemical Manual
("Copper Sulfate") or other qualitative method.
Once every 4 hours
Surface profile is checked after process

(if applicable).
Per load
Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE C - Conversion Coatings (Phosphate, Non-phosphate, Chromate, Non-chrome)

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
C1.1
Actual Condition
Minimum Requirement
Conversion Coating
1.4
C1.2
C1.3
1.4
1.6
2.11
2.12
2.0
This audit requires the completion of either

Table A and/or B.
n/a
n/a
If the pretreatment and phosphate is not a continuous

process, there shall be a part cleanliness check
immediately before phosphate. Acceptance criteria
must be defined.
Manual
Every start of production cycle and change

of lot number and each container.
Automatic
Confirm set-up at the start of production

and every process change.
maintenance.
Time
Conditioner (If Applicable)
C2.1
1.4
2.11
2.12
Pressure/Agitation
Automatic
Once every 8 hours
C2.2
1.4
2.11
2.12
Chemical Concentration
Automatic/Manual
For continuous operations, once every 8

hours. Otherwise, prior to start of each
production cycle.
C2.3
2.11
There is a dump schedule for conditioner.
Manual
Once per week
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
3.0
Actual Condition
Minimum Requirement
Conversion Coating Bath
C3.1
1.4
2.11
2.12
Pressure/Agitation
Automatic
Once every 8 hours
C3.2
1.4
2.11
2.12
Temperature is monitored and controlled if required by

chemical manufacturer's technical
Automatic
data sheet.
Once every 8 hours
C3.3
1.4
2.11
2.12
Chemical Analysis:
- Phosphate: Free Acid, Total Acid, Iron Content, pH,
Accelerator Amount as Applicable
- Non-phosphate: Concentration, pH
- Chromate: Concentration, pH
- Non-chrome: Concentration, pH
Automatic/Manual
Once every 4 hours
C3.4
1.4
2.11
2.12
Fluoride Ion Concentration (if aluminum is being

coated)
Automatic/Manual
Once every 4 hours
C3.5
1.4
1.6
2.11
2.12
Coating Weight/Thickness
Manual
Once every 8 hours*
C3.6
1.4
2.11
2.12
Crystal/Grain Size (If applicable)
Manual
Per customer requirement
C3.7
Coverage of phosphate coating is visually inspected for

Manual
absence of voids.
Once every 8 hours
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
4.0
Actual Condition
Minimum Requirement
Rinse After Phosphate
C4.1
1.4
2.11
2.12
Cleanliness of last rinse

- visual inspection for suspended solids
- verify water flow (1/shift)
Automatic/Manual
Once every 8 hours
C4.2
1.4
2.11
2.12
Pressure/Agitation
Automatic
Once every 8 hours
C4.3
2.11
Manual
Once per week
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
5.0
Actual Condition
Minimum Requirement
C5.1
1.4
2.11
2.12
Pressure/Agitation
Automatic
Once every 8 hours
C5.2
1.4
2.11
2.12
Chemical Concentration
Automatic/Manual
Once every 8 hours
C5.3
1.4
2.11
2.12
Temperature is monitored and controlled if required by

chemical manufacturer's technical
Automatic
data sheet.
Once every 8 hours
C5.4
2.11
There is a dump schedule for seal.
Manual
Once per week
Automatic
Once every 8 hours
6.0
C6.1
C6.2
Dry-Off (If Applicable)

1.4
2.11
2.12
1.4
2.11
Air temperature is monitored and controlled.
There is a procedure to ensure dryness of parts prior to

Visual
subsequent coating.
Every change of lot number and each

container.
Actual Condition
(Pass / Fail / N/A)
CQI-12

PROCESS TABLE D - Powder Coating

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
D1.1
D2.2
Minimum Requirement
Powder Paint Application

1.4
2.11
2.0
D2.1
Actual Condition
Parts are checked exiting dry-off oven for cleanliness

and trapped water, prior to entering powder booth.
Manual
Once every hour
Powder Booth and Equipment

1.4
2.11
2.12
1.4
1.6
2.11
2.12
The temperature of parts entering the coating booth is

Automatic/Manual
monitored.
Conveyor speed set point is verified. If conveyor is not

Automatic/Manual
used, time in oven is verified.
Once every 8 hours
Automatic Line: Confirm set-up at the start

of production and every process change.
maintenance.
Manual Line: Continuously monitor time in
each stage of process.
D2.3
1.4
2.11
2.12
D2.4
1.4
2.11
2.12
The ground is checked using a 500 volt mega ohm

meter (less than 1megaohm resistance).
Manual
At start-up, every process change and

once every 8 hours.
All guns are properly assembled (e.g., electrodes and

deflectors are installed and not damaged).
Manual
Prior to the start of production and once

every 8 hours.
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
1.4
2.11
2.12
The voltage and the current setting of the spray gun is

Manual
defined and verified for each process and part.

once every 8 hours.
D2.6
1.4
2.11
2.12
For automatic systems gun settings are defined and

verified for each process and part.
- Deflector
- Gun to part distance
- Number of guns
- Spacing of guns
- Reciprocator settings

once every 8 hours.
D2.7
1.4
1.17
2.11
2.12
The air dryer output temperature and dew point need to

be measured. The filter on main compressed air line
Automatic/Manual
needs to be monitored.
Prior to start of production and once every

4 hours. With a control alarm, frequency
may be reduced to once every 8 hours.
D2.8
1.4
1.17
2.11
2.12
The booth temperature and humidity are checked.

D2.5
Automatic
Automatic
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
D2.9
1.4
2.11
2.12
D2.10
1.4
1.17
2.11
2.12
D2.11
Actual Condition
Minimum Requirement
The air balance in the powder booth is checked.
Automatic/Manual

Every sieve is clean and operational.
Automatic/Manual

every 8 hours.
1.4
2.11
2.12
The powder flow on sieve is monitored.
Automatic/Manual

every 8 hours.
D2.12
1.4
2.11
2.12
The feed hopper fluidizing air pressure is checked.
Manual

every 8 hours.
D2.13
1.4
2.11
2.12
The dust vent on feed hopper is checked.
Manual

every 8 hours.
D2.14
1.4
1.17
2.11
2.12
The reclaim sieve is operating properly.
Manual

every 8 hours.
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
D2.15
1.4
1.17
2.11
2.12
D2.16
Actual Condition
Minimum Requirement
The venturis (orifice or block) in the feed pumps and

the pick up tubes in the hopper are checked.
Manual

every 8 hours.
1.4
2.11
2.12
The feed hoses are checked to ensure that they have

no excessive bends and kinks.
Manual

every 8 hours.
D2.17
1.4
2.11
2.12
The virgin to reclaim powder ratio is defined for each

part and/or process. Verified by feed pressures, weight Manual
or volume.
Once every 8 hours
D2.18
1.4
1.17
2.11
2.12
The pressure differential across the filters in the booth

Automatic
collection chamber is monitored.

every 8 hours.
D2.19
1.4
2.11
2.12

every 8 hours.
3.0
Cure (See Cure Process Table I)
Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE E - Spray

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
E1.1
Actual Condition
Minimum Requirement
Part Appearance
1.4
2.11
Pretreated parts are visually inspected for

cleanliness and/or uniform phosphate coating or
paint layer (when applicable). This must be
performed between each coating layer.
Manual
Once every 4 hours
E1.2
1.4
2.9
Mutilation prevention items (i.e., gloves, belt buckle

Manual
covers, watch covers, etc.) are in place.
Ongoing
E1.3
1.4
1.17
2.11
2.12
Paint racks and/or fixtures are visually inspected for

cleanliness, excessive paint build-up, bent hooks,
Manual
etc.
Each time parts are racked/loaded.
E1.4
1.4
1.17
2.11
2.12
There is a paint rack/fixture maintenance program.

Manual
Program must define rack/fixture cleaning intervals.
Surface profile is within specifications

(if applicable).
Manual
Once every 4 hours
Surface tension is within specifications

(if applicable).
Manual
Once every 4 hours
1.4
2.11
2.13
E1.5
1.4
E1.6
2.11
2.13
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
2.0
Actual Condition
Minimum Requirement
Paint Mixing
E2.1
1.4
2.11
2.12
Paint mixing rooms are controlled (mixing tank

grounding, closed container, properly enclosed
space, temperature, clean environment).
E2.2
1.4
2.11
2.12
There is a stock rotation system (FIFO) in place and

being utilized to ensure that older material is used
Manual
first.
Continuous
E2.3
1.4
1.6
1.17
2.11
2.12
Paint agitation/time and reduction (solvent package)

Manual
are proper and documented.
Once every 8 hours
E2.4
1.4
1.6
1.17
2.11
2.12
Viscosity is verified to be within operational limits

and documented.
Prior to start of production and every

process change and/or addition. For
continuous operations check once every 8
hours.
E2.5
1.4
1.6
1.17
2.11
2.12
Temperature is verified to be within operational limits

Automatic/Manual
and documented.
Automatic/Manual
Manual
Once every 8 hours

process change and/or addition. For
continuous operations check once every 8
hours.
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
E2.6
1.4
1.6
1.17
2.11
2.12
The proper filter size and type are in place.
E2.7
1.4
1.6
1.17
2.11
2.12
Pump pressures are set and pressure readings are

verified and documented to be within operational
Manual
limits.
Prior to start of production, every process

change and once every 8 hours.
E2.8
1.4
2.11
2.12
Circulation (flow meter, pressure gage) is monitored

Automatic/Manual
and documented.

E2.9
1.4
2.11
2.12
Filters are in use (not by-passed) and pressures

monitored. Filters are changed before pressure
differential exceeds 10 PSI.
(70 kPa)

Manual
Automatic/Manual

process change.
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
3.0
Actual Condition
Minimum Requirement
Primer/Promoter
E3.1
1.4
1.17
2.11
2.12
E3.2
Destaticizing air is operational. (Plastic parts only).
Automatic

1.4
2.11
2.12
Booth balance (air flow) is monitored and

documented.
Manual

E3.3
1.4
1.6
1.17
2.11
2.12
Booth temperature and humidity are monitored and

Automatic/Manual
documented.

E3.4
1.4
1.6
1.17
2.11
2.12
Atomizer parameters (fluid flow, air pressures

(atomizing fan, shaping), electrostatics and mixing)
are set within operational limits.

process change. For continuous
operations once per day.
Automatic/Manual
For manual process, prior to start of

production and every process change.
E3.5
1.4
1.6
Time is verified and documented if applicable.
Automatic/Manual
For automated process, verify once per

month, or after every program change or
major maintenance.
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
4.0
Actual Condition
Minimum Requirement
Basecoat (If applicable)
E4.1
1.4
1.6
2.11
2.13
E4.2
1.4
1.6
1.17
2.11
2.12

Automatic/Manual
documented.

E4.3
1.4
1.6
1.17
2.11
2.12


Flashtimes between coats are set at suppliers

recommended times.
Automatic/Manual
Automatic/Manual
At the start of production and every

process change.

E4.4
1.4
1.6
Automatic/Manual
For automated process, verify 1 per

major maintenance.
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
Basecoat Heated Flash

(Waterborne Materials Only)
5.0
E5.1
1.4
1.6
2.11
2.12
Oven set point(s) and energy type

(Convection/IR/UV/etc.), are verified to be within
chemical suppliers recommended limits and
documented.
Manual

operations once every 8 hours.
E5.2
1.4
1.6
2.11
2.12
Oven temperature is monitored and recorded.
Automatic
Prior to start of production and every two

hours. With a temperature control alarm,
frequency may be reduced to once every 8
hours.
E5.3
1.4
1.6
2.11
2.12
For each coating in use, proper cure or drying time

parameters are verified based upon product
technical data sheet.
Manual
Every three months and after oven

modification or repair.
E5.4
1.17
Air filter (if used) change is scheduled.
Manual
E5.5
1.4
1.6
2.11
2.13
Percent solids after pre-dry is at the suppliers

recommended percentage.
Manual
Once every 8 hours
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
6.0
Actual Condition
Minimum Requirement
Clear coat
E6.1
1.4
1.6
2.11
2.13
E6.2
1.4
1.6
1.17
2.11
2.12

Automatic/Manual
documented.

E6.3
1.4
1.6
1.17
2.11
2.12


Flashtimes between coats are set at suppliers

recommended times.
Automatic/Manual
Automatic/Manual
At the start of production and every

process change.

E6.4
7.0
1.4
1.6
Automatic/Manual
For automated process, verify 1 per

major maintenance.
Actual Condition
(Pass / Fail / N/A)
CQI-12

PROCESS TABLE F - Electrocoat

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
F1.1
Actual Condition
Minimum Requirement
Pre-Electrocoat Paint Application Part Appearance

1.4
2.11
2.0
Pretreated parts are visually inspected for cleanliness and/or

uniform phosphate coating (when phosphate is used).
Manual
Once every 8 hours
Bath parameters (pH, conductivity, solid content, temperature,

voltage) are checked and adjusted.
Automatic/Manual
Once every 8 hours
Electrocoat Tank
F2.1
1.4
2.11
2.12
F2.2
1.4
2.11
2.12
Oil contamination (Panel inspection for pin holes).

Oil bags must be available.
Manual
Once per month and if any visual defects

are observed.
F2.3
1.4
1.6
2.11
2.12
Cycle time/Line speed setup is checked.
Automatic/Manual

production and every part change. For
automated process, at the start of
F2.4
1.4
2.11
2.12
Is bath circulation monitored.

(Flow meter, pressure gage)
Automatic/Manual
Once every 4 hours. With a control alarm,

frequency may be reduced to once every 8
hours.
F2.5
1.4
2.11
2.12
Bag filters are in use (not by-passed) and pressures monitored.

Filter bags changed before pressure differential exceeds 10
Manual
PSI. (70 kPa)
Filter mesh size must be 25 m maximum.
Once every 8 hours
F2.6
1.4
2.11
2.12
Flow over the weir is verified.
Manual
Once every 8 hours
F2.7
1.4
2.11
2.12
Bath is checked for microbial contamination.
Manual
Once every month*
F2.8
1.4
2.11
2.12
Incoming DI / RO water is checked for cleanliness. (Conductivity

Automatic/Manual
<10 S/mhos )
Once every 8 hours
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
F2.9
1.4
1.17
2.11
2.12
Paint racks and/or barrels are visually inspected for cleanliness,

Manual
excessive paint build-up, bent hooks, etc.
Each time parts are racked/loaded
F2.10
1.4
1.17
2.11
2.12
There is a paint rack/barrel maintenance program. Program

must define rack/barrel cleaning intervals.
Manual
F2.11
1.4
2.11
2.12
Saddle contact cleanliness (if applicable).
Manual
Once every 8 hours
F2.12
1.4
1.17
2.11
2.12
There is a tank cleaning and maintenance schedule.
Manual
Once every year
F2.13
1.4
2.11
2.12
Confirmation of ash content (pigment to binder ratio).
Manual
Once per month
F2.14
1.4
2.11
2.12
Analysis of accumulation of metallic impurities.
Manual
Once every 6 months
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
3.0
Actual Condition
Minimum Requirement
F3.1
1.4
2.11
2.12
The conductivity of the anolyte solution has been measured.
Manual
Once every 8 hours
F3.2
1.4
2.11
2.12
The pH of the anolyte solution has been measured.
Manual
Once every 8 hours
F3.3
1.4
2.11
2.12
Oil contamination (Panel inspection for pin holes).

Oil bags must be available.
Manual
Once every month
F3.4
1.4
2.11
2.12
The anolyte solution is being circulated to each cell.
Automatic/Manual
Once every 8 hours
F3.5
1.4
2.11
2.12
Dump and clean schedule for anolyte is being maintained.
Manual
F3.6
1.4
2.11
2.12
Amperage draw has been checked on anodes.
Automatic/Manual
4.0
Rectifier
F4.1
1.4
1.6
2.11
2.12
The proper voltage is being used for the load size.

(Electronically Controlled with digital read-out)
Manual
When each bar or rack enters the coating

tank.
F4.2
1.4
2.11
2.12
The ramp up time to full voltage has been verified.
Automatic/Manual
Once every 6 months or after any change

or maintenance of rectifier.
F4.3
2.10
There is a visual indicator to alert personnel when system is

energized.
Automatic
Ongoing
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
F4.4
1.4
1.17
2.11
2.12
The ripple of the rectifier has been checked by an approved

electrician.
Automatic/Manual
Actual Condition
Minimum Requirement
Once per year or after any change or

maintenance of rectifier.
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
5.0
Actual Condition
Minimum Requirement
Rinse System
F5.1
1.4
2.11
2.12
Immersion rinse tanks are operating at the proper levels and

tanks are being agitated correctly.
Automatic/Manual
Once every 8 hours
F5.2
1.4
2.11
2.12
There is sufficient permeate supplied to the rinse.
Automatic/Manual
Once every 8 hours
F5.3
1.4
2.11
2.12
The pH and conductivity of the DI rinse water are measured. (If

Manual
part of production process).
F5.4
1.4
2.11
2.12
F5.5
1.4
2.11
2.12
Bag filters are in use (not by-passed) and pressures monitored.

Filter bags changed before pressure differential exceeds 10
Manual
PSI. (70 kPa)
Filter mesh size must be 25 m maximum.
Once every 8 hours
F5.6
1.4
1.17
2.11
2.12
Rinse tanks and related equipment are emptied, inspected and

Manual
cleaned.
6.0
Ultra filters are in use (not by-passed) and pressures monitored.
Automatic/Manual
Once every 8 hours
Once every 8 hours
Actual Condition
(Pass / Fail / N/A)
CQI-12

PROCESS TABLE G - Dip/Spin

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
G1.3
G1.4
2.9
1.4
2.11
1.4
2.11
1.17
2.6
2.9
G1.5
G1.6
G1.7
Actual Condition
Minimum Requirement
Coating Material Application
G1.1
G1.2
2.9
1.4
Final pretreatment and/or phosphating shall be

completed in the same building.
Yes/No
Ongoing
After pretreatment, parts are inspected for flash rust,

wetness, oil or other defects.
Manual
Every lot
Pretreated parts are visually inspected for cleanliness

and/or uniform phosphate coating (when phosphate is Automatic/Manual
used).
Once every 8 hours
Containers used to hold parts between coating

operations are free of oil, grease or other
contaminants.
Yes/No
Ongoing
Parts shall be stored indoors in a staging area that

does not affect the quality of parts. The staging area
shall not be adjacent to open doorways or windows
exposing parts to water, dirt, and other
contaminations.
Yes/No
Ongoing
2.11
Parts shall be coated within the time limit specified by

Per application manual
the chemical supplier application manual.
Ongoing
2.11
Prior to loading into coating machines, parts are

inspected for flash rust, wetness, oil or other defects.
Every lot
1.4
Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
2.0
Actual Condition
Minimum Requirement
Coating Bath
G2.1
1.4
2.11
2.12
Incoming paint viscosity is checked.
Manual
Each new lot of paint
G2.2
1.4
2.11
2.12
Incoming solids checks are performed.
Manual
Each new lot of paint
G2.3
1.4
1.17
2.11
2.12
Appropriate mixing equipment is used, capable of

dispersing settled solids.
Manual
Ongoing
Coating material (paint) must be stored per chemical

supplier requirements.
Manual
Ongoing
When not in use, coating material (paint) is kept

covered and/or sealed per chemical supplier
requirements.
Manual
Ongoing
Paint storage area is clean and organized so each

paint is easily found and to prevent contamination.
Manual
Ongoing
Paint filtration procedures are in place.
Preventive maintenance
schedule
Ongoing
Automatic/Manual
Prior to start of production and once every 3

hours.
G2.4
G2.5
G2.6
G2.7
2.9
2.10
2.9
2.10
2.9
2.10
2.9
2.10
The following checks shall be performed during

production:
G2.8
G2.9
1.4
2.11
2.12
Paint Temperature
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
G2.10
1.4
2.11
2.12
Viscosity
Manual

hours.
G2.11
1.4
2.11
2.12
Basecoat % Solids (by weight).
Manual
Prior to start of production and every process

change and/or addition. For continuous
G2.12
1.4
2.11
2.12
Volume (paint depth in coating vat).
Automatic/Manual

hours.
G2.13
1.4
2.11
2.12
Equipment surfaces in contact with wet coating (ex.

Vibratory feed tables) are free of loose debris and
excess coating build-up.
Manual
Once per day
G2.14
1.4
1.17
2.11
2.12
Basket condition (basket mesh clean and

undamaged).
Manual
Once per day
G2.15
1.4
2.11
2.12
Paint and/or viscosity reducing agent additions are

documented and the viscosity verified before
production continues.
Manual
Each addition
G2.16
2.10
Viscosity cups are cleaned after each use.
Manual
Ongoing
G2.17
2.14
1.17
Viscosity cups are verified against calibrated

standards or master cup.
Manual
Twice per month
G2.18
2.14
1.17
Thermometers are verified against calibrated

standards.
Manual
Once per month
Actual Condition
(Pass / Fail / N/A)
CQI-12


Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
3.0
G3.1
G3.2
G3.3
G3.4
Actual Condition
Minimum Requirement
Application Parameters
1.4
1.6
1.4
1.6
1.4
1.6
1.4
1.6
1.17
A system is in place to ensure proper basket weights

for specific parts, such as processing manual, traveler, Automatic/Manual
or process recipe.
Every lot
Baskets are kept less than 2/3 full by volume.
Automatic/Manual
Every lot
Coating parameters are controlled and verified via

external display (dip time, spin speed, spin time, spin
cycle, spin direction and tumbling).
Automatic/Manual
Every lot
There is a system (raking, vibe table, etc.) to uniformly

distribute parts prior to curing to ensure proper cure
Automatic/Manual
and prevent parts from sticking and minimize touch
marks.
Every lot
G3.5
2.10
Vibratory feed tables are cleaned (if used).
Manual
As needed
G3.6
2.9
There is evidence of steps taken to assist in soft

handling of parts (shallow drops, lined chutes and
hoppers, bumper boards, etc.).
Automatic/Manual
Every lot
Parts are cool to touch before each coating step.
Manual
Every lot
G3.7
1.4
2.9
2.11
4.0
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE H - Autodeposition

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
Actual Condition
Minimum Requirement
Coating Bath
H1.1
1.4
2.11
2.12
H1.2
1.4
1.6
2.11
2.12
H1.3
Mixer speed and direction are monitored and

adjusted.
Automatic/Manual
Once every 8 hours
Temperature of the coating bath is continuously

monitored and controlled.
Automatic
Continuous monitoring by controller and

manually verified once per day.
1.4
2.11
2.12
Misting nozzles in the vicinity of the coating bath

are operational.
Automatic/Manual
Once every 8 hours
H1.4
1.4
2.11
2.12
Acid (e.g., 101 meter) and oxidation/reduction

potential (ORP) levels are checked.
Automatic/Manual
Once every 2 hours
H1.5
1.4
2.11
2.12
Chemical concentration (% solids, starter/iron

Automatic/Manual
titration, conductivity) is checked and maintained.
Once every 8 hours
H1.6
1.4
1.17
2.11
2.12
Coating tank, mixers and heating/cooling system

are inspected and maintained.
Once every 12 months
Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE H - Autodeposition

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
2.0
Actual Condition
Minimum Requirement
Tap Rinse After Coating
H2.1
1.4
2.11
2.12
Pump pressure or agitator speed is monitored.
Automatic/Manual
Once every 8 hours
H2.2
1.4
2.11
2.12
Impurity concentration (conductivity) is checked.
Automatic/Manual
Once every 8 hours
3.0
Reaction Rinse
H3.1
1.4
2.11
2.12
Chemical concentration is checked and

maintained.
Automatic/Manual
Once every 8 hours
H3.2
1.4
2.11
2.12
Pump pressure or agitator speed is monitored.
Automatic/Manual
Once every 8 hours
H3.3
1.4
2.11
2.12
Temperature is monitored and controlled if

required by chemical manufacturer's technical
data sheet.
Automatic/Manual
Once every 8 hours
H3.4
1.4
1.17
2.11
2.12
There is a dump schedule.
Manual
Per Chemical Manufacturer's

recommendation and production volume.
4.0
Actual Condition
(Pass / Fail / N/A)
CQI-12

PROCESS TABLE I - Cure

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
1.0
I1.1
Oven conditions are monitored and recorded continuously by a

data recorder.
Convective - Temperature
Gas IR - Gas flow
Electric IR - Power (wattage)
Automatic

I1.2
Oven and part temperature profile is verified. The verification

shall be performed under production load conditions and with
thermocouples located to cover all areas of the part curing
window.
Manual
Once every 3 months and after oven

I1.3
1.4
1.6
2.11
2.12
For each coating in use, proper cure or drying time parameters

are verified based upon oven temperature profile and product
technical data sheet.
Manual
Once every 3 months and after oven

I1.4
1.4
1.6
1.17
2.11
2.12
Conveyor speed set point is verified. If conveyor is not used,

time in oven is verified.
Automatic/Manual

production and every part change. For
automated process, at the start of
Air filter (if used) change is scheduled.
Manual
Per oven manufacturer, filter supplier

recommendation.
I1.5
I1.6
2.13
Cure testing is performed per part specification on a production

Manual
part.
At oven start-up, every process change

and once every 8 hours.
I1.7
2.13
Coating adhesion test is performed per part specification on a

production part.
Manual

I1.8
2.13
Appearance requirements checks (color, gloss etc.) are

performed per part specification.
Manual

Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE J: Anodizing and Hard Coat Anodizing

* When historical results show capability, test frequency may be reduced.
Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
1.0
Actual Condition
Minimum Requirement
Cleaning (Alkaline or Acid)
J1.1
1.4
2.11
2.12
Temperature
Automatic

J1.2
1.4
2.11
2.12
Cleaner Concentration
Manual
Once per day *
J1.3
1.4
2.11
2.12
Soil loading ( i.e., acid split, alkalinity ratio)
Manual
Once per day *
J1.4
1.4
2.11
2.12
Time
J1.5
1.4
2.11
2.12
Agitation (Consistent Across tank)
Automatic
Once every 8 hours
J1.6
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J1.7
1.4
2.11
2.12
Skimmer Weir Level/oil separator function
Automatic or Manual
Once every 8 hours

production and every process change. *
Automatic or Manual
For automated process, verify after every
program change or major maintenance.
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
J1.8
1.4
2.11
2.12
Oil on top of tank
Manual
Once every 8 hours
J1.9
1.4
2.11
2.12
Debris in bottom of tank
Manual
Once every 8 hours
J1.10
1.4
2.11
2.12
Metal Contamination (as applicable)
Manual
Once every 8 hours
Automatic or Manual
Once every 8 hours
2.0
Rinsing
J2.1
1.4
2.11
2.12
Solution Level
J2.2
1.4
2.11
2.12
Contamination accumulation/build up on side

Manual Visual
of tanks
Once per week *
J2.3
1.4
2.11
2.12
There is a process for control of biological

contamination
Manual
Once per week *
J2.4
1.4
2.11
2.12

Agitation or flow for immersion tanks.
Automatic/Manual
Once every 8 hours
J2.5
1.4
2.11
2.12
Temperature (if controlled)
Automatic

J2.6
1.4
2.11
2.12

Time
Automatic or Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
J2.7
1.4
2.11
2.12
J2.8
2.11
3.0
Actual Condition
Minimum Requirement
Cleanliness of last rinse

- visual inspection for oil or suspended
contaminants
- overflow
- debris in bottom of tank
Manual
Once per day
Manual
Deoxidizer / Desmutter
J3.1
1.4
2.11
2.12
Automatic or Manual

J3.2
1.4
2.11
2.12
Concentration
Manual
Once per day *
J3.3
1.4
2.11
2.12
Acidity Ratio (Total Acid/ Free Acid = Ratio)
Manual
Once per day *
J3.4
1.4
2.11
2.12
Time
J3.5
1.4
2.11
2.12
Automatic
Once every 8 hours
J3.6
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J3.7
1.4
2.11
2.12
Manual
Once per day

production and every process change. *
Automatic or Manual
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
4.0
Actual Condition
Minimum Requirement
Chemical Etch / Strip (alkaline or acid)
J4.1
1.4
2.11
2.12
Automatic or Manual

J4.2
1.4
2.11
2.12
Concentration
Manual
Once per day *
J4.3
1.4
2.11
2.12
Contamination:
For alkaline: aluminum content
Manual
Once per day *
J4.4
1.4
2.11
2.12
Contamination accumulation/build up on side

Manual
of tanks
Once per week
J4.5
1.4
2.11
2.12
For acid etches only:

Ratio (Total Acid/ Free Acid = Ratio)
For acid: fluoride content
Manual
Once per day *
J4.6
1.4
2.11
2.12
Time
Automatic or Manual
J4.7
1.4
2.11
2.12
Automatic
Once every 8 hours
J4.8
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J4.9
1.4
2.11
2.12
Manual
Once per day
For manual process: every load.

process change or major maintenance.
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
5.0
Actual Condition
Minimum Requirement
Bright Dip
J5.1
1.4
2.11
2.12
Temperature
Automatic or Manual
Continuous monitoring by controller with

low temperature alarm. Manually verify
prior to start of production and once every
4 hours.
J5.2
1.4
2.11
2.12
Acid concentration
Manual
Once every 4 hours
J5.3
1.4
2.11
2.12
Specific gravity
Manual
Once every 4 hours
J5.4
1.4
2.11
2.12
Contamination: aluminum content
Manual
Once per week
J5.5
1.4
2.11
2.12
Contamination accumulation, suspended

solids
Manual
Once per day
J5.6
1.4
2.11
2.12
Time
Automatic or Manual
J5.7
1.4
2.11
2.12
Automatic
Once every 8 hours
J5.8
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 4 hours

Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
6.0
Actual Condition
Minimum Requirement
Bright Dip Rinse
J6.1
1.4
2.11
2.12
Acid concentration or specific gravity
Manual
Once every 8 hours
J6.2
1.4
2.11
2.12
Time
Automatic or Manual
Once every 8 hours
J6.3
1.4
2.11
2.12
Agitation (Consistent Across Tank)
Manual
Once every 8 hours
J6.4
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J6.5
1.4
2.11
2.12
Manual
Once per week
J6.6
1.4
2.11
2.12
Temperature
Automatic or Manual
Once per day
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
7.0
Actual Condition
Minimum Requirement
Anodizing
J7.1
1.4
2.11
2.12
Temperature
Automatic

J7.2
1.4
2.11
2.12
Acid Concentration
Manual
Once every 8 hours *
J7.3
1.4
2.11
2.12
Concentration of additives (fume

suppressant, hard coat additives, high
temperature additives)
Manual
Once per week
J7.4
1.4
2.11
2.12
Aluminum Content (maximum 20 g/L)
Manual
Once per week
J7.5
1.4
2.11
2.12
Time
Automatic or Manual

Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
Actual Condition
Minimum Requirement
J7.6
1.4
2.11
2.12
Manual
Once every 8 hours
J7.7
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J7.8
1.4
2.11
2.12
Manual
Once per week
J7.9
1.4
2.11
2.12
Voltage or Amperage with Gradual Ramp Up

Automatic or Manual
(Current Increase)
J7.10
1.4
2.11
2.12
Saddle Contact Cleanliness
Manual

process change and major maintenance.
Once every 8 hours
Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
8.0
Actual Condition
Minimum Requirement
Dye
J8.1
1.4
2.11
2.12
Temperature
Automatic

J8.2
1.4
2.11
2.12
Concentration
Manual
Once per day *
J8.3
1.4
2.11
2.12
pH
Manual
J8.4
1.4
2.11
2.12
Time
Automatic or Manual
J8.5
1.4
2.11
2.12
Agitation (as applicable)
Automatic
Once every 8 hours
J8.6
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J8.7
1.4
2.11
2.12
Manual
Once every 8 hours
J8.8
1.4
2.11
2.12
There is a process for control of biological

contamination.
Manual
Once per week *

Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
9.0
Actual Condition
Minimum Requirement
Pre-Seal (If applicable)
J9.1
1.4
2.11
2.12
Automatic or Manual

J9.2
1.4
2.11
2.12
Concentration
Manual
Once per week *
J9.3
1.4
2.11
2.12
pH
Manual
J9.4
1.4
2.11
2.12
Time
Automatic or Manual
J9.5
1.4
2.11
2.12
Automatic
Once every 8 hours
J9.6
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J9.7
1.4
2.11
2.12
Manual
Once every 8 hours

Actual Condition
(Pass / Fail / N/A)
CQI-12

Item #
Related
CSA
Question #
Type of Control
Minimum Requirement
10.0
Actual Condition
Minimum Requirement
Seal (if Applicable)

J10.1
1.4
2.11
2.12
Time
Automatic or Manual
J10.2
1.4
2.11
2.12
Temperature
Automatic or Manual

Manually verify every 4 hours if controlled.
J10.3
1.4
2.11
2.12
Concentration
Manual
J10.4
1.4
2.11
2.12
pH
Manual
J10.5
1.4
2.11
2.12
Contamination (per chemical vendor

recommendation)
Manual
Once per week *
J10.6
1.4
2.11
2.12
Manual
Once every 8 hours
J10.7
1.4
2.11
2.12
Solution Level
Automatic or Manual
Once every 8 hours
J10.8
1.4
2.11
2.12
Manual
Once every 8 hours

Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE K - EQUIPMENT

Item #
Related
CSA
Question #
K1.1
2.14
pH / Conductivity Meter
K1.2
2.14
pH / Conductivity Probe
Solution compatible probes must
be used.
K1.3
2.14
Temperature Controller
Equipment Type
Pretreatment/
Aqueous
Cleaning
Powder
Coat
E-Coat
Spray
Dip/Spin
A-Coat
Cure
Anodize
Verification Frequency
Calibration /
Certification
Frequency *
Daily
Once per year
Before each use
N/A
Every 3 months
N/A
Ripple Checked every 12

months
N/A
PROCESS EQUIPMENT
X
K1.4
2.14
Rectifier
K1.5
2.14
Amp Meter/Volt Meter
Checked every 12 months
N/A
K1.6
2.14
Wet Analysis:
Before use, chemicals must be
checked for shelf life and/or
expiration date
Daily
N/A
K1.7
2.14
Filters
Per process table
N/A
K1.8
2.14
Laboratory Balance (Weight

Scale)
Once per month
N/A
K1.9
2.14
Conductivity Meter
Once per month
N/A
K1.10
2.14
Viscosity cup
K1.11
K1.12
2.14
Twice per month
N/A
N/A
Once every 6 months
N/A
Once per year
Thermocouple
Lab Oven Controller
Daily per ASTM B117
N/A
Daily
N/A
N/A
MINIMUM REQUIRED TESTING CAPABILITY

K2.1
2.14
Salt Spray Cabinet
K2.2
2.14
Water Immersion bath
K2.3
2.14
Cure Testing
Per Part
K2.4
2.14
Adhesion Testing
Per Part
N/A
K2.5
2.14
Thickness Testing
Per Part
Once per year
K2.6
2.14
Solids Testing
Daily
N/A
Included in Preventative
Maintenance Plan
Comment
CQI-12
PROCESS TABLE L - Part Inspection and Testing

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to specifications or other
requirements.
Note that not all tests are applicable to all coatings.
Item #
Related
CSA
Question #
Minimum Requirement
1.0
L1.1
1.4
Procedures are in place to prevent damage to the finish or part

during the inspection and packaging processes.
System in place
L1.2
Appearance of the coating shall be verified per specification and

Ongoing
applications manual.
L1.3
Initial adhesion
(Tape, bend, impact)
At the start of production and once every

8 hours.
L1.4
Intercoat / final adhesion
Per customer specification
L1.5
Color and Gloss (If applicable)
At the start of production and once every

8 hours.
L1.6
Film thickness / coating weight
At the start of production, every part family

change and every process change. Once
every 8 hours.
Actual Condition
(Pass / Fail / N/A)
CQI-12
PROCESS TABLE L - Part Inspection and Testing

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to specifications or other
requirements.
Note that not all tests are applicable to all coatings.
Item #
Related
CSA
Question #
Minimum Requirement
L1.7
Corrosion resistance:
- Neutral salt spray
- Humidity
- Water immersion
Once per week per line per coating

process being used.
If the same coating system is used for
multiple customers with different
requirements, test to the highest
requirement.
L1.8
Torque tension/Coefficient of Friction
Once per week per line per coating

process being used.
L1.9
Dimensional check (e.g., Go-no go, Plug and Ring gage)
L1.10
Hydrogen Embrittlement
L1.11
Cyclical Corrosion Testing
Actual Condition
(Pass / Fail / N/A)

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CQI-12v2

Special Process: Coating System Assessment

AIAG Copyright and Trademark Notice:

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment 2nd Edition

Type(s) of Coating Processes at this Facility:

Current Quality Certification(s):

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

Number of "Fail" Findings in the Job Audit(s):

Number of Process Table Items not meeting Minimum Requirements:

2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment (General Facility Overview)

Requirements and Guidance

Section 1 - Management Responsibility and Quality Planning

Is there a dedicated and

To ensure readily available expertise, there shall be a

Does the coater perform

The coater shall incorporate a documented advanced

2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment (General Facility Overview)

Requirements and Guidance

The coater shall incorporate the use of a documented

The coater shall incorporate the use of a documented

2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment (General Facility Overview)

Requirements and Guidance

Are all coating related and

To ensure all customer requirements are both

Is there a written process

The coater shall have written process specifications for

2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment (General Facility Overview)

Requirements and Guidance

To demonstrate each process is capable of yielding

The analysis of products and processes over time can

Are internal assessments

2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment (General Facility Overview)

Requirements and Guidance

The quality management system shall include a

Does the Quality Department

The coater shall define a process for continual

Does the Quality Manager or

The quality management system shall include a

The Quality Manager or designee is responsible for

2012 AIAG (Automotive Industry Action Group)

Special Process: Coating System Assessment

Version 2 Issued 2/2012

Special Process: Coating System Assessment (General Facility Overview)

Requirements and Guidance

There shall be procedures or work instructions

Are there procedures or work